Sometime this spring/summer I am going to build a new roll cage for my CJ. I am currently buliding my tube bender and am starting to look at the dies that I am going to need. What radius works best for roll cages? I am going to use 1.75" DOM 0.120" wall. I was thinking of using the 6" CLR Die.

All my tube work has been with a 1-3/4"x6"CLR die as well. It's a great size for a cage. At that thickness you might be able to go tighter with DOM or cromoly, but on HREW I wouldn't go much smaller because it will start to neck down in the bend area with smaller CLRs. Plus you may want to use it for thinner wall tubing in the future

Can someone show some pictures of how to properly tie the cage to the frame. I have seen some other methods of how some folks have done it and it does not appear to the safest method.

Also would it be best to leave the original bar and build off of it or just build an entirely new cage. I purchased the jeep with this already done and figured it would be best to just remove everything and start over.

Will 1.75 tube be ok for my truck, or should I go with 2" for the main hoops ?

The truck is a fullsize ramcharger (hence my screen name), and will most likely weigh in around 6000 lb when done. it weighs 5200 right now, with only a 6 pt bar and 1/2 ton axles, as well as a SB engine, & stock bumpers.

A BB, 1 ton or rockwell axles, and larger tires, as well as a full cage are planned.

I have a protools 105 HD bender, and will be converting it to hydraulic once I get the stand built. I currently have a 1.75 x 6 clr die, and if I can safely use 1.75, I'd like to do it. If not, I'll just get another die for the 2".

1.75 should be fine. Most of your strength will be in the design. Triangulate well and you don't need 2"
NHRA only requires 1 5/8" for (as far as I know) down to 6.50 et.
Unless you plan to run faster than 200mph or just wanna jump off a cliff with it you shouldn't need to be stronger than those cars are.

this is a TJ cage with a 7 inch radius.....i know nobody really ever uses this large of radius on cages, but the die was on sale when i bought the bender......sorry bout the pic quality i dont have any others at the moment.....

1.75 should be fine. Most of your strength will be in the design. Triangulate well and you don't need 2"
NHRA only requires 1 5/8" for (as far as I know) down to 6.50 et.
Unless you plan to run faster than 200mph or just wanna jump off a cliff with it you shouldn't need to be stronger than those cars are.

I agree on the speed part, but if it does fall on it's roof, it weighs probably twice as much as the cars in the nhra

I hear ya there, but I figure if it can take a hard hit on top when a car rolls on it's side and slams into the wall, it can probably take the hit of a truck rolling over on it. Even going end-over would be less impact than the drag cars take.